Fuel Tanks: The Essential Guide to Safe and Efficient Fuel Storage

Whether you’re running a backup generator, a fleet of vehicles, or an industrial operation, having a reliable fuel storage system is essential. Fuel tanks provide a safe and efficient way to store diesel, petrol, biodiesel, or other liquid fuels, ensuring that you always have a steady supply of fuel when needed.

A fuel tank is a storage container designed to hold and protect fuel from contamination, evaporation, and leaks. They come in various sizes, materials, and designs, each suited for different applications, from small portable tanks to large industrial fuel storage systems.

In this guide, we’ll explore what fuel tanks are, how they work, different types, materials, safety considerations, and best practices for fuel storage. By the end, you’ll have a complete understanding of how to choose the right fuel tank for your needs.

What Is a Fuel Tank?

A fuel tank is a container used to store liquid fuel for use in engines, generators, industrial machinery, and heating systems. It is designed to prevent leaks, evaporation, and contamination, ensuring that fuel remains safe and ready for use.

Key Features of a Fuel Tank

✅ Secure Fuel Storage – Prevents leaks, spills, and evaporation.
✅ Corrosion-Resistant Materials – Made from steel, aluminium, or plastic for durability.
✅ Ventilation & Pressure Control – Ensures safe pressure levels inside the tank.
✅ Leak Prevention & Spill Containment – Includes bunded (double-skin) designs for extra safety.
✅ Compatible with Various Fuels – Stores diesel, petrol, biodiesel, kerosene, and other liquid fuels.

Fuel tanks are essential for industries that rely on fuel-powered equipment, ensuring uninterrupted operations and fuel security.

How Does a Fuel Tank Work?

A fuel tank is more than just a storage container—it includes various components that help manage fuel flow, pressure, and safety.

Step-by-Step Fuel Storage Process

1️⃣ Fuel is stored in the tank, protected from air, water, and contaminants.
2️⃣ Ventilation systems regulate pressure to prevent fuel vapour buildup.
3️⃣ Fuel lines and pumps transfer fuel to generators, vehicles, or machinery as needed.
4️⃣ Filtration systems remove impurities, ensuring clean fuel for efficient combustion.
5️⃣ Sensors and monitoring systems track fuel levels, preventing shortages or overfilling.

These features ensure that fuel remains stable and ready for use, whether in transport, power generation, or industrial applications.

Types of Fuel Tanks

Fuel tanks come in various designs and configurations, depending on storage needs, fuel type, and location.

1. Above-Ground Fuel Tanks (AGT)

• Installed on the surface for easy access and maintenance.
• Used in farms, fuel stations, industrial facilities, and transport depots.
• Available in single-skin and double-skin (bunded) designs.

🔹 Pros: Easy to inspect, install, and relocate.
🔹 Cons: More exposed to weather, theft, and physical damage.

2. Underground Fuel Tanks (UGT)

• Installed below ground to save space and improve security.
• Common in petrol stations, airports, and large industrial sites.

🔹 Pros: Saves space, offers better temperature control.
🔹 Cons: Expensive installation, harder to inspect for leaks.

3. Portable Fuel Tanks

• Small, mobile fuel storage containers for transporting fuel safely.
• Used for refuelling generators, construction equipment, and remote locations.

🔹 Pros: Highly mobile, easy to use.
🔹 Cons: Limited fuel capacity.

4. Bunded Fuel Tanks (Double-Skin Fuel Tanks)

• Features two layers of protection—an inner tank and an outer bund to contain leaks.
• Required by law in many industries for environmental protection.

🔹 Pros: Best for spill prevention and regulatory compliance.
🔹 Cons: More expensive than single-skin tanks.

5. Vertical & Horizontal Fuel Tanks

• Vertical tanks save space and are used in fuel depots and industrial plants.
• Horizontal tanks are more common for vehicle refuelling and backup generators.

6. Aviation & Marine Fuel Tanks

• Specially designed to store aviation fuel (Jet A-1) and marine diesel.
• Built with anti-corrosion coatings and specialised safety features.

Choosing the right type of fuel tank depends on storage requirements, fuel type, and safety regulations.

Fuel Tank Materials: Steel vs. Plastic

Fuel tanks are made from different materials, each with advantages and disadvantages.

For long-term industrial use, steel fuel tanks are preferred, while plastic tanks are ideal for portable and small-scale applications.

Safety and Regulations

Fuel storage poses risks of leaks, fires, and contamination, making safety regulations essential.

1. Leak Prevention & Spill Containment

• Double-skin fuel tanks (bunded tanks) prevent leaks from contaminating the environment.
• Regular inspections help detect cracks, rust, or damage early.

2. Fire & Explosion Safety

• Tanks should be stored away from heat sources and ignition points.
• Explosion-proof vents help release pressure buildup safely.

3. Compliance with Fuel Storage Regulations

• Many countries require bunded fuel tanks for commercial and industrial use.
• Secondary containment systems must hold at least 110% of the tank’s capacity.

4. Proper Ventilation & Pressure Control

• Prevents fuel vapour buildup, which can lead to explosions or tank ruptures.

By following fuel tank safety regulations, businesses can prevent accidents, reduce costs, and comply with environmental laws.

Best Practices for Fuel Tank Maintenance

Proper fuel tank maintenance ensures long-lasting performance and safe fuel storage.

✅ Regular Inspections – Check for leaks, corrosion, and fuel contamination.
✅ Fuel Polishing & Filtration – Prevents sludge, water buildup, and microbial growth.
✅ Tank Cleaning – Removes sediments and impurities every 1–2 years.
✅ Monitor Fuel Levels – Avoids running out of fuel or overfilling.
✅ Protect Against Water Contamination – Use water separators and store tanks in dry locations.

Following these maintenance practices ensures fuel stays clean, safe, and ready for use.

Conclusion

A fuel tank is a critical component in industries that rely on diesel, petrol, biodiesel, or alternative fuels. Whether you need a portable tank for generators, a bunded tank for industrial storage, or an underground tank for fuel stations, choosing the right fuel tank ensures safety, efficiency, and regulatory compliance.

By investing in proper fuel storage solutions and maintenance, businesses can reduce costs, prevent environmental risks, and ensure uninterrupted fuel supply.